Electrode production process

Abstract

A method for forming at least one electrode, said method comprising: a) providing an electronically conductive, inert material; b) cutting the substrate material to form at least one current collector; c) placing at least one current collector on a carrier; d) applying one or more protection layers to one or both sides of the current collector to form a coated electrode; and e) removing the electrode from the carrier.

The invention claimed is: 
     
       1. A method for forming an electrode, said method comprising:
 a) providing an electronically conductive, inert material; 
 b) cutting the electronically conductive, inert material to form at least one current collector; 
 c) placing at least one current collector on a carrier, wherein the carrier comprises two plates and wherein either one plate, or both plates, comprises at least one opening defining an electrochemically active zone of the electrode, and wherein the at least one current collector is placed between the two plates such that an inner region of each current collector is exposed and an outer region of the current collector is overlapped by the carrier; 
 d) applying one or more protection layers to one or both sides of the current collector to form the electrode; and 
 e) removing the electrode from the carrier. 
 
     
     
       2. The method according to  claim 1 , wherein a plurality of current collectors is placed on the carrier. 
     
     
       3. The method according to  claim 1 , wherein each current collector comprises an electrode tab. 
     
     
       4. The method according to  claim 1 , wherein the electrode has a length of between 1 cm and 30 cm and a width of between 1 cm and 40 cm. 
     
     
       5. The method according to  claim 1 , wherein the carrier is formed of a that is selected from stainless steel, copper or aluminium. 
     
     
       6. The method according to  claim 1 , wherein the region of overlap of the carrier on the current collector extends from between 0.01 mm and 20 mm from the edge of the current collector. 
     
     
       7. The method according to  claim 1 , wherein both plates comprise at least one opening defining an electrochemical zone; wherein the openings on each plate are substantially aligned with one another such that each current collector has an exposed area defining an electrochemical zone on both sides, and wherein said exposed areas are substantially aligned with one another; and wherein the one or more protective layers are applied to both sides of the current collector simultaneously.